MIM Case Study – ContactMIM Case Study – Contact• Application: Medical Electronics• Functional Requirements:

Structurally intact; low thermal expansion

• Competing Technology: Stamped flat base, welded wire for posts

• Overall Size: – Base 0.25 mm thick, 1.25 mm

square– Posts 0.5 mm diameter x 1.2

mm tall

• Part Weight: 0.007 grams• Material: MIM-Alloy 42,

subsequent Ni & Au plating

MIM Case Study – ContactMIM Case Study – Contact

- Small Part!- MIM to replace existing

process:- Base stamped out of gold-

plated sheet- Posts made from wire

form welded to base• - MIM seen as a cost savings

with better consistency

Key Characteristics- ContactKey Characteristics- Contact

Parts needs to be solderable to the circuit board; bumps molded in to allow flow of solder under part

One of two posts intact

No cracks

Minimal flash

Posts strong enough to not deflect when wire is welded to posts; center support section added

MIM Case Study – ContactMIM Case Study – Contact

• Why MIM?– More consistent position of posts– Connection of the posts to the base is more reliable in a one-

piece MIM part than the welded wire to the stamped base. – MIM Alloy 42 consistent with expected material properties– Economics of MIM regarding CAPEX, part price significantly

better than stamp & weld– MIM a more repeatable for high-volume technology for this

application

MIM Case Study – ContactMIM Case Study – Contact